Test system and method for a wiring harness

ABSTRACT

Test system and methods for testing a wiring harness. In one embodiment, a remote tester of the test system includes a connector member comprising a terminal end having one or more terminals configured to mate with terminals in an electrical connector of the wiring harness, and a tester control member integrated on a back end. The tester control member includes a housing that protrudes from the back end of the connector member, test circuitry electrically coupled to the terminals of the connector member, a wireless transceiver that communicates with a central controller to receive a test program, and a battery. The test circuitry performs a test on the wiring harness based on the test program, and reports test results to the central controller.

FIELD

This disclosure relates to the field of test systems, and moreparticularly, to test systems for wiring harnesses.

BACKGROUND

A wiring harness is an assembly of wires that are bound together, andelectrical connectors that terminate the wires. Wiring harnesses aretypically used to provide electrical connectivity between devices in anaircraft, a spacecraft, a vehicle, a boat, etc. Fabrication of a wiringharness may include acquiring lengths of wire, and placing the wires ona formboard, a jig board, an assembly board, etc. The formboard ismarked with the pathways or routes for the wires. Based on the design ofthe wiring harness, groups of wires may be routed in differentdirections to form branches of the wiring harness. At some point, groupsof wires may be bound together by a sheath (e.g., over-braiding), andthe ends of the wires are connected to terminals of the electricalconnectors to complete the wiring harness. During or after fabrication,the wiring harness is attached to an electrical testing device to verifyand test electrical connections of the wiring harness. Some wiringharnesses may have hundreds or thousands of individual wires thatprovide connectivity between multiple electrical connectors. It istherefore desirable to identify effective and efficient test systems andmethods for testing wiring harnesses.

SUMMARY

Embodiments described herein include a test system and associatedmethods for testing a wiring harness. A test system as described hereinincludes remote testers that individually couple with electricalconnectors of the wiring harness. The remote testers run a test processas orchestrated by a central controller, which wirelessly communicateswith the remote testers. Each of the remote testers is a self-containedunit configured to perform one or more tasks of the test process. Aremote tester includes a connector that electrically couples with anelectrical connector of a wiring harness, and a control portion that isintegrated on the back side of the connector. The structuralconfiguration of the remote testers allows the entire remote tester unitto directly couple with an electrical connector of the wiring harness.One benefit is that no additional cabling is needed to couple a remotetester to the wiring harness, as the remote tester directly couples withthe wiring harness. Another benefit is that a wiring harness may betested during fabrication or after installation in an aircraft or thelike due to the size of the remote testers, the direct coupling of theremote testers with the wiring harness, and the distributed manner ofthe test system.

One embodiment comprises a remote tester of a wiring harness testsystem. The remote tester comprises a connector member comprising aterminal end having one or more terminals configured to mate withterminals in an electrical connector of a wiring harness, and a back endopposite the terminal end. The remote tester further comprises a testercontrol member integrated on the back end of the connector member. Thetester control member includes a housing that protrudes from the backend of the connector member, test circuitry within the housing that iselectrically coupled to the terminals of the connector member, awireless transceiver within the housing that is configured tocommunicate with a central controller of the wiring harness test systemto receive a test program, and a battery within the housing that isconfigured to provide power to the test circuitry and the wirelesstransceiver. The test circuitry is configured to perform a test on thewiring harness based on the test program, and to report test results tothe central controller via the wireless transceiver.

In another embodiment, the housing includes a side wall disposed betweenthe back end of the connector member and an end wall.

In another embodiment, the housing further includes a removable accesscover at the end wall that allows access to an interior of the housing.

In another embodiment, the housing has a cylindrical shape that fullyencloses the battery, the wireless transceiver, and the test circuitry.

In another embodiment, outer dimensions of the housing correspond withouter dimensions of the connector member.

In another embodiment, the tester control member further includes acharging port configured to interface with a charging connector tocharge the battery.

In another embodiment, the tester control member further includes apairing button configured to activate a pairing mode, and a pairingindicator configured to indicate that the remote tester is paired withthe central controller.

In another embodiment, the tester control member further includes aconnector indicator configured to display an electrical connectoridentifier for the electrical connector of the wiring harness.

Another embodiment comprises a wiring harness test system that comprisesa a plurality of remote testers and a central controller. The remotetesters are configured to couple with electrical connectors of a wiringharness, and the central controller is configured to communicatewirelessly with the remote testers. The remote testers include aconnector member comprising a terminal end having one or more terminalsconfigured to mate with terminals in one of the electrical connectors ofthe wiring harness, and a back end opposite the terminal end. The remotetesters further include a tester control member integrated on the backend of the connector member. The tester control member includes ahousing that protrudes from the back end of the connector member, testcircuitry within the housing that is electrically coupled to theterminals of the connector member, a wireless transceiver within thehousing that is configured to communicate with the central controller toreceive a test program, and a battery within the housing that isconfigured to provide power to the test circuitry and the wirelesstransceiver. The test circuitry is configured to perform a test on thewiring harness based on the test program, and to report test results tothe central controller via the wireless transceiver.

In another embodiment, the housing includes a side wall disposed betweenthe back end of the connector member and an end wall.

In another embodiment, the housing further includes a removable accesscover at the end wall that allows access to an interior of the housing.

In another embodiment, the test circuitry is configured to selectivelyinject a current onto one or more of the terminals of the connectormember, and to selectively monitor for current on one or more of theterminals of the connector member.

In another embodiment, the wiring harness comprises a wiring harness ofan aircraft.

In another embodiment, the tester control member further includes acharging port configured to interface with a charging connector tocharge the battery.

In another embodiment, the wiring harness test system further comprisesa charging station comprising a plurality of docking ports. The dockingports include the charging connector configured to couple with thecharging port.

In another embodiment, the charging station further includes a batterylevel indicator at the docking ports configured to indicate a batterylevel of the battery in one of the remote testers.

In another embodiment, the charging station further includes a testselection indicator at the docking ports configured to indicate whethera remote tester is selected for the test process on the wiring harness.

In another embodiment, the tester control member further includes apairing button configured to activate a pairing mode, and a pairingindicator configured to indicate that a remote tester is paired with thecentral controller.

In another embodiment, the tester control member further includes aconnector indicator configured to display an electrical connectoridentifier for one of the electrical connectors of the wiring harness.

Another embodiment comprises a method of testing a wiring harness. Themethod comprises selecting remote testers of a wiring harness testsystem that mate with electrical connectors of the wiring harness,pairing the remote testers with a central controller of the wiringharness test system, coupling the remote testers to the electricalconnectors of the wiring harness, and performing a test process. Thetest process includes transmitting a test program from the centralcontroller to the remote testers via wireless signals, performing a teston the wiring harness based on the test program via the remote testers,reporting test results for the test process from the remote testers tothe central controller via wireless signals, and verifying a conditionof the wiring harness at the central controller based on the testresults.

The features, functions, and advantages that have been discussed can beachieved independently in various embodiments or may be combined in yetother embodiments, further details of which can be seen with referenceto the following description and drawings.

DESCRIPTION OF THE DRAWINGS

Some embodiments of the present invention are now described, by way ofexample only, with reference to the accompanying drawings. The samereference number represents the same element or the same type of elementon all drawings.

FIG. 1 illustrates a wiring harness.

FIG. 2 is a wire harness test system in an illustrative embodiment.

FIGS. 3-4 are perspective views of a remote tester in an illustrativeembodiment.

FIG. 5 is a schematic diagram of a remote tester and a centralcontroller in an illustrative embodiment.

FIG. 6 is a schematic diagram of test circuitry in a remote tester in anillustrative embodiment.

FIG. 7 is another perspective view of a remote tester in an illustrativeembodiment.

FIG. 8 is another schematic diagram of a remote tester in anillustrative embodiment.

FIG. 9 illustrates a charging station in an illustrative embodiment.

FIG. 10 is a flow chart illustrating a method of testing a wiringharness in an illustrative embodiment.

FIG. 11 illustrates remote testers coupled to electrical connectors of awiring harness in an illustrative embodiment.

FIG. 12 illustrates the terminal ends of remote testers in anillustrative embodiment.

FIG. 13 is a block diagram illustrating a point-to-point continuity testin an illustrative embodiment.

DETAILED DESCRIPTION

The figures and the following description illustrate specific exemplaryembodiments. It will be appreciated that those skilled in the art willbe able to devise various arrangements that, although not explicitlydescribed or shown herein, embody the principles described herein andare included within the contemplated scope of the claims that followthis description. Furthermore, any examples described herein areintended to aid in understanding the principles of the disclosure, andare to be construed as being without limitation. As a result, thisdisclosure is not limited to the specific embodiments or examplesdescribed below, but by the claims and their equivalents.

FIG. 1 illustrates a wiring harness 100. Wiring harness 100 is anassembly of wires and electrical connectors, where groups of wires arebound together and the electrical connectors terminate the wires. Forexample, wiring harness 100 includes wire bundles 101-110, andelectrical connectors 111-120 that act as termination points for wirebundles 101-110. A wire bundle 101-110 is a grouping of individual,insulated wires (not visible) that are bound by a tie, an over-braid, asheath, a cover, a casing, etc. An electrical connector 111-120 is adevice that terminates the wires of a wire bundle 101-110 with terminals(e.g., male pins or female sockets). Electrical connectors 111-120 aregenerally characterized by their pinout, physical construction, size,insulation between terminals, etc. Wiring harness 100 also includes oneor more exterior sheaths 130 that bind one or more wire bundles 101-110.Exterior sheaths 130 may comprise a thermoplastic, an over-braid, etc.Wiring harness 100 may be fabricated for an aircraft, a spacecraft, avehicle, a boat, or another type of machine. The configuration of wiringharness 100 as shown in FIG. 1 is just one example, and other wiringharnesses are considered herein.

FIG. 2 is a wiring harness test system 200 in an illustrativeembodiment. Wiring harness test system 200 is a system configured toperform tests on a wiring harness, such as continuity tests,high-potential tests, pin-setting tests, and/or other types of tests. Inthis embodiment, wiring harness test system 200 comprises a plurality ofremote testers 211-220, and a central controller 230. At a high level,the tasks of testing are distributed to remote testers 211-220. Remotetesters 211-220 are discrete components configured to connect withelectrical connectors of a wiring harness. Remote testers 211-220 areconfigured to wirelessly communicate with central controller 230, andpossibly with each other. Remote testers 211-220 may each communicatewith central controller 230 on different frequencies or channels, or maybe individually addressable on a common frequency or channel. Centralcontroller 230 is a device that manages remote testers 211-220 toperform a test process. Central controller 230 transmits one or moretest programs (e.g., set of commands or instructions) to remote testers211-220 via wireless signals. The remote testers 211-220 execute tasksbased on the test program to test the wiring harness, and report testresults back to central controller 230. Central controller 230 maycomprise a desktop computer, a laptop, a mobile phone running anapplication, or another type of processing device.

One technical benefit of wiring harness test system 200 is that small,lightweight remote testers 211-220 may be coupled with the electricalconnectors of the wiring harness to perform the tests, instead ofrelying on a heavy and cumbersome back-wired assembly on a formboard orthe like. Also, because wiring harness test system 200 is highlyportable, a wiring harness may be tested in situ, such as when thewiring harness is installed in an aircraft or the like.

FIGS. 3-4 are perspective views of remote tester 211 in an illustrativeembodiment. Remote tester 211 may have a unibody structure, or may becomprised of multiple pieces attached or affixed to form an integralobject. In this embodiment, remote tester 211 includes a connectormember 310 and a tester control member 320. Connector member 310 is theportion of remote tester 211 that couples to an electrical connector ofa wiring harness. Thus, connector member 310 has a terminal end 312 thatis configured to mate with an electrical connector of a wiring harness.In other words, the physical design of terminal end 312 is configuredsuch that terminal end 312 is able to mate with or plug into anelectrical connector of a wiring harness. For this design, terminal end312 includes one or more terminals 314 (i.e., an electrical terminal)configured to mate with corresponding terminals in an electricalconnector of a wiring harness. Terminal end 312 may comprise a plug asillustrated in FIG. 3 having male pins as terminals 314. In otherembodiments, terminal end 312 may comprise a receptacle having femalesockets as terminals 314. Although terminal end 312 is illustrated as acylindrical body, terminal end 312 may have other shapes to mate with anelectrical connector. Other remote testers 212-220 in FIG. 2 may have asimilar design as remote tester 211, although the physical structure ofthe connector member 310 may vary between remote testers 211-220 toaccommodate different types of electrical connectors on a wiringharness.

Opposite the terminal end 312 of connector member 310 is back end 316(also referred to as the backshell end). Tester control member 320 isintegrated on back end 316 of connector member 310, which means thattester control member 320 is directly attached, affixed, or formed intoback end 316 of connector member 310. Tester control member 320 includesa housing 322 that projects or protrudes from back end 316 of connectormember 310 axially in a direction opposite terminal end 312 along alongitudinal axis 350 of remote tester 211. Housing 322 is an enclosurethat includes one or more side walls 324 disposed between back end 316of connector member 310 and an end wall 326. Housing 322 may partiallyor fully enclose the electronics of tester control member 320 (e.g., abattery, a wireless transceiver, and test circuitry), which is describedin more detail in FIG. 5. As shown in FIG. 4, end wall 326 may include aremovable access cover 428 that allows access to the interior of housing322, and the components within the interior of housing 322. Housing 322may have a cylindrical shape as shown in FIGS. 3-4, or may have othershapes. Also, the size of housing 322 (i.e., the outer dimensions 328)may correspond with the size of connector member 310 (i.e., the outerdimensions 318) by being substantially similar, which more easily allowsremote tester 211 to test a wiring harness in situ. The physicalstructure of remote tester 211 shown in FIGS. 3-4 is just one example,and the physical structure may vary as desired.

FIG. 5 is a schematic diagram of remote tester 211 and centralcontroller 230 in an illustrative embodiment. As shown in FIGS. 3-4,remote tester 211 includes connector member 310 and tester controlmember 320. Tester control member 320 includes a battery 502, a wirelesstransceiver 504, and test circuitry 506 that are contained withinhousing 322. Battery 502 is configured to provide power to remote tester211 (i.e., wireless transceiver 504 and test circuitry 506). Battery 502may be replaceable or rechargeable, and may comprise a Nickel Cadmium, aLithium Ion, or another type of battery. Wireless transceiver 504comprises circuitry, hardware, antennas, and/or means configured tocommunicate with other devices (e.g., central controller 230) viawireless or Radio Frequency (RF) signals. Wireless transceiver 504 mayuse a variety of protocols for communication, such as Bluetooth (overIEEE 802.15.1), ZigBee (over IEEE 802.15.4), Wi-Fi (over IEEE 802.11),or another protocol. Test circuitry 506 comprises circuitry, hardware,logic, or means that is electrically coupled to terminals 314 ofconnector member 310. Thus, test circuitry 506 is electrically connectedto the terminals of an electrical connector when connector member 310 isplugged into the electrical connector. Test circuitry 506 isprogrammable and re-programmable with a test program 508 via centralcontroller 230. A test program 508 comprises a set of commands orinstructions specifying actions to perform for a test. Based on testprogram 508, test circuitry 506 may selectively inject a current to oneor more terminals 314, and/or may selectively monitor or sense forcurrent on one or more terminals 314. Test circuitry 506 may also reporttest results to central controller 230, and possibly to other remotetesters 212-220. Remote tester 211 may include additional elements notspecifically described herein.

Central controller 230 includes a processor 522, a wireless transceiver524, and a memory 526. Processor 522 comprises circuitry or hardwarethat controls or manages testing of a wiring harness. Wirelesstransceiver 524 comprises circuitry, hardware, antennas, and/or meansconfigured to communicate with remote testers 211-220 via wireless or RFsignals. Memory 526 is a computer readable storage medium for data,instructions, applications, etc., and is accessible by processor 522.Central controller 230 manages the testing of a wiring harness (e.g.,wiring harness 100) by programming remote testers 211-220, and receivingtest results from remote testers 211-220. Thus, memory 526 may storetest programs for testing different wiring harnesses. For example,memory 526 may store test program 508 for testing wiring harness A, andmay also store test program 509 for testing wiring harness B, testprogram 510 for testing wiring harness C, etc. Test programs 508-510 maybe provisioned for continuity testing, high-potential testing,pin-setting testing, or other types of testing. A continuity testverifies electrical connections between terminals of one electricalconnector and terminals of other electrical connectors for a wiringharness. A high-potential test verifies isolation between wires,terminals, etc., of the wiring harness. A pin-setting test verifies thata terminal on one electrical connector is electrically connected to thecorrect terminal on another electrical connector for the wiring harness.Central controller 230 may include additional elements not specificallydescribed herein.

FIG. 6 is a schematic diagram of test circuitry 506 in an illustrativeembodiment. In this embodiment, test circuitry 506 is electricallycoupled to four terminals 314 of connector member 310. Test circuitry506 may include a terminal circuit 600 for each terminal 314. In thisembodiment, terminal circuit 600 includes a switch 602 connected betweenbattery 502 and terminal 314. Switch 602 represents a type of switchingelement configured to be selectively opened and closed by test circuitry506 to inject a current onto terminal 314 based on test program 508,such as a transistor. Terminal circuit 600 also includes a switch 606and a load 608 (indicated by a resistor) connected between terminal 314and ground, and a current sensor 610 configured to monitor or sense acurrent passing through load 608. Switch 606 represents a type ofswitching element configured to be selectively opened and closed by testcircuitry 506 to allow a current to pass through load 608. Currentsensor 610 represents a type of sensing element that is configured tosense a current passing through load 608 (and also passing throughterminal 314) based on test program 508. With this design, testcircuitry 506 is configured to selectively inject a current onto aterminal 314, and to sense a current on the terminal 314 as part of thetest program.

FIGS. 7-8 show additional elements that may be added to remote tester211 (and the other remote testers 212-220). FIG. 7 is anotherperspective view of remote tester 211 in an illustrative embodiment. Inthis figure, tester control member 320 of remote tester 211 may furtherinclude a charging port 702 that is electrically coupled with battery502 (see FIG. 5) to allow for recharging of battery 502. Charging port702 is configured to interface with a charging connector on a chargingcable, charging station, etc., to charge battery 502. Charging port 702may comprise a USB, a mini-USB, a micro-USB, or another connector type.Charging port 702 may be disposed on end wall 326 or side wall 324 asdesired.

Tester control member 320 of remote tester 211 may further include apairing button 704 and/or a pairing indicator 706. Pairing button 704 iselectrically coupled with wireless transceiver 504 (see FIG. 5), and isconfigured to activate a pairing mode for remote tester 211 (i.e.,through wireless transceiver 504). Pairing indicator 706 comprises alight (e.g., LED), an audible alarm, or some other instrument. Pairingindicator 706 may be configured to indicate that remote tester 211 is inpairing mode (e.g., a flashing light), and that remote tester 211 ispaired with central controller 230 (e.g., a solid light). Pairing button704 and/or a pairing indicator 706 may be disposed on end wall 326 orside wall 324 as desired. In another embodiment, pairing of wirelesstransceiver 504 may be activated by central controller 230, through acharging station, etc.

Remote tester 211 may further include a connector indicator 708.Connector indicator 708 comprises lights (e.g., LEDs), a display, orsome other hardware component that presents information in visual form.Connector indicator 708 is configured to display an identifier (ID), alabel, or other information descriptive of an electrical connector of awiring harness. As remote tester 211 is to be mated with a particularelectrical connector of a wiring harness for a test process, connectorindicator 708 is configured to display an electrical connector ID orother information specific to an electrical connector so that remotetester 211 is coupled with the proper electrical connector. For example,the electrical connector ID may comprise a number or series of numbers,one or more letters, or other symbols mapped to an electrical connector.Connector indicator 708 may be disposed on end wall 326 or side wall 324as desired.

FIG. 8 is another schematic diagram of remote tester 211 in anillustrative embodiment. This figure schematically shows charging port702, pairing button 704, pairing indicator (IND) 706, and connectorindicator 708 for tester control member 320.

Wiring harness test system 200 as described herein may further include acharging station. FIG. 9 illustrates a charging station 900 in anillustrative embodiment. Charging station 900 is configured to charge aplurality of remote testers 211-220. In this embodiment, chargingstation 900 includes a plurality of docking ports 902, and each of thedocking ports 902 includes a charging connector 904 configured to couplewith a charging port on a remote tester 211-220 (e.g., charging port702). Therefore, when remote testers 211-220 are coupled to dockingports 902, charging station 900 operates to charge the remote testers211-220. Charging station 900 may further include a battery levelindicator 910 at each of the docking ports 902 configured to indicatethe battery level of a remote tester 211-220. For example, battery levelindicator 910 may comprise one or more lights or LEDs. Charging station900 may further include a test selection indicator 912 at each of thedocking ports 902 configured to indicate whether a remote tester 211-220is selected for a test process on a particular wiring harness. Forexample, a controller 920 on charging station 900 may be programmed witha mapping of which remote tester 211-220 is docked at which docking port902. As described above, some remote testers 211-220 may have differenttypes of terminal ends 312 for mating with different types of electricalconnectors, and some of remote testers 211-220 may have the same typesof terminal ends 312. To avoid confusion, controller 920 may communicatewith central controller 230 through wireless signals or a wiredconnection to receive information on the remote testers 211-220 thatwill be used for a test process on a particular wiring harness.Controller 920 may then activate test selection indicator 912 at thedocking port 902 for those remote testers 211-220 scheduled for the testprocess on the wiring harness. For instance, test selection indicator912 may comprise a light or LED that is illuminated by controller 920.An operator may therefore be able to see which of remote testers 211-220are scheduled for a test process.

FIG. 10 is a flow chart illustrating a method 1000 of testing a wiringharness in an illustrative embodiment. The steps of method 1000 will bedescribed with reference to wiring harness test system 200 in FIG. 2,but those skilled in the art will appreciate that method 1000 may beperformed in other systems. Also, the steps of the flow charts describedherein are not all inclusive and may include other steps not shown, andthe steps may be performed in an alternative order.

It is assumed for method 1000 that a wiring harness (e.g., wiringharness 100) is fabricated, or is in the process of being fabricatedsuch as on a formboard. Remote testers 211-220 of wiring harness testsystem 200 are selected for a test process that mate with electricalconnectors 111-120 of wiring harness 100 under test (step 1002). Aswiring harness 100 may have a variety of electrical connectors 111-120of different sizes, shapes, pinouts, etc., the proper remote testers211-220 are selected so that the connector members 310 match theelectrical connectors 111-120. When remote testers 211-220 are docked atcharging station 900, for example, central controller 230 may transmitinformation to charging station 900 indicating which of remote testers211-220 are selected for the test process. In response to theinformation, controller 920 of charging station 900 may activate thetest selection indicator 912 at the docking ports 902 to indicate theselected remote testers 211-220 (optional step 1003).

Remote testers 211-220, which are selected for the test process, arepaired with central controller 230 (step 1004), and may also be pairedwith one another. Generally, pairing enables two devices to communicatewith each other. For example, wireless transceivers 504 in remotetesters 211-220 may enter a discovery mode to be discoverable by centralcontroller 230, such as by pressing pairing button 704. Wirelesstransceiver 524 in central controller 230 detects the wirelesstransceivers 504 in remote testers 211-220, and establishes wirelesscommunications between remote testers 211-220 and central controller230. Wireless transceiver 504 in remote testers 211-220 may activatepairing indicator 706 when paired with central controller 230 so that anoperator may verify that remote testers 211-220 are paired.

Remote testers 211-220 are coupled to the electrical connectors 111-120of wiring harness 100 (step 1006). As part of step 1006, centralcontroller 230 may transmit an electrical connector identifier (ID) toeach of remote testers 211-220 indicating a specific electricalconnector 111-120 of wiring harness 100 that is targeted for couplingwith a remote tester 211-220. In response, test circuitry 506 of remotetesters 211-220 displays the electrical connector ID at connectorindicator 708 (optional step 1007). An operator may therefore viewconnector indicator 708 to determine which remote tester 211-220 coupleswith which electrical connector 111-120 of wiring harness 100. FIG. 11illustrates remote testers 211-220 coupled to electrical connectors111-120 of wiring harness 100 in an illustrative embodiment.

Remote testers 211-220 and central controller 230 then perform the testprocess (step 1008). In wiring harness test system 200, centralcontroller 230 acts as the master to initiate commands to remote testers211-220, and remote testers 211-220 act as slaves by responding to thecommands from central controller 230. Therefore, central controller 230transmits a test program 508 to remote testers 211-220 via wirelesssignals (step 1010). Central controller 230 may be programmed with awiring diagram for wiring harness 100, and the test program 508 isconfigured to perform tests via remote testers 211-220 based on thewiring diagram. Test program 508 comprises a set of commands orinstructions that direct the operation of remote testers 211-220.Central controller 230 may transmit the same test program to each of theremote testers 211-220, and the remote testers 211-220 may determinewhich commands to perform from the test program. Alternatively, centralcontroller 230 may transmit a subset of the commands from test program508 (i.e., tester-specific commands) to the remote testers 211-220indicating the commands each remote tester 211-220 is directed toperform for the overall test program. Remote testers 211-220 receivetest program 508 through wireless transceiver 504 (see FIG. 5), andstore test program 508 at test circuitry 506.

Remote testers 211-220 perform one or more tests on wiring harness 100based on the test program 508 (step 1012). For example, test circuitry506 on remote tester 211 may execute one or more commands from testprogram 508 to apply a potential between a terminal A and ground (e.g.,through a ground wire, ground shield, etc., of wiring harness 100) toinject a current onto terminal A. Concurrently, test circuitry 506 onremote tester 212 may execute one or more commands from test program 508to monitor for the current on terminal B. If the current, injected atterminal A of remote tester 211, is sensed at terminal B of remotetester 212, then wiring harness 100 provides point-to-point connectivitybetween these two terminals. Remote testers 211-220 then report testresults for the test process to central controller 230 via wirelesssignals (step 1014). The test results may indicate a pass/fail status, acurrent measurement, or other results. Central controller 230 verifiesthe condition of wiring harness 100 based on the test results (step1016). For example, central controller 230 may indicate a pass or failcondition of wiring harness 100, a location of an incomplete connection(e.g., due to damage wire, improperly seated terminal, etc.), a locationor worn or damaged insulation on a wire, or other information, such asto an operator via a user interface, over a network, etc.

Method 1000 or the test process (step 1008) may be performed one or moretimes, and at different stages of fabrication or installation of wiringharness 100. For example, the test process may be performed beforeover-braiding of wiring harness 100 so that damaged or broken wires,incomplete connections, etc., may be repaired before over-braiding. Thetest process may be performed after over-braiding to verify thecondition of wiring harness 100 before installation of wiring harness100. Further, the test process may be performed while wiring harness 100is installed (in situ) in an aircraft or other machine. In situ testingis one particular benefit of wiring harness test system 200. Becauseremote testers 211-220 are compact units that directly couple withelectrical connectors 111-120 of wiring harness 100, they may be usedfor tests after wiring harness 100 is installed in an aircraft of thelike.

The following provides an example of a test process. FIG. 12 illustratesthe terminal ends 312 of remote testers 211-214 in an illustrativeembodiment. Remote tester 211 includes terminals 1211-1216, remotetester 212 includes terminals 1221-1224, remote tester 213 includesterminals 1232, 1234-1236, and 1238, and remote tester 214 includesterminals 1243, 1245, and 1247-1249. It is assumed for this embodimentthat remote testers 211-214 are coupled with electrical connectors111-114 of wiring harness 100 (see FIG. 11), which have similarpin-outs. For the test process, central controller 230 downloads a testprogram 508 to remote testers 211-214, which execute the test program508 to perform a continuity test. FIG. 13 is a block diagramillustrating a point-to-point continuity test in an illustrativeembodiment. For the test process, remote tester 211 injects a currentonto terminal 1211, and remote tester 212 monitors for the current onterminal 1222. If remote tester 212 detects the current on terminal1222, then continuity is verified along a current path over wiringharness 100 between these terminals. Similarly, remote tester 211injects a current onto terminal 1212, and remote tester 212 monitors forthe current on terminal 1221. If remote tester 212 detects the currenton terminal 1221, then continuity is verified along a current path overwiring harness 100 between these terminals. Remote testers 211-214 mayperform the tests as illustrated in FIG. 13, and report test resultsback to central controller 230.

Any of the various elements or modules shown in the figures or describedherein may be implemented as hardware, software, firmware, or somecombination of these. For example, an element may be implemented asdedicated hardware. Dedicated hardware elements may be referred to as“processors”, “controllers”, or some similar terminology. When providedby a processor, the functions may be provided by a single dedicatedprocessor, by a single shared processor, or by a plurality of individualprocessors, some of which may be shared. Moreover, explicit use of theterm “processor” or “controller” should not be construed to referexclusively to hardware capable of executing software, and mayimplicitly include, without limitation, digital signal processor (DSP)hardware, a network processor, application specific integrated circuit(ASIC) or other circuitry, field programmable gate array (FPGA), readonly memory (ROM) for storing software, random access memory (RAM),non-volatile storage, logic, or some other physical hardware componentor module.

Also, an element may be implemented as instructions executable by aprocessor or a computer to perform the functions of the element. Someexamples of instructions are software, program code, and firmware. Theinstructions are operational when executed by the processor to directthe processor to perform the functions of the element. The instructionsmay be stored on storage devices that are readable by the processor.Some examples of the storage devices are digital or solid-statememories, magnetic storage media such as a magnetic disks and magnetictapes, hard drives, or optically readable digital data storage media.

As used in this application, the term “circuitry” may refer tohardware-only circuit implementations (such as implementations in onlyanalog and/or digital circuitry), combinations of hardware circuits andsoftware, and hardware circuit(s) and or processor(s), such as amicroprocessor(s) or a portion of a microprocessor(s), that requiressoftware (e.g., firmware) for operation, but the software may not bepresent when it is not needed for operation. A combination of hardwarecircuits and software may include a combination of analog and/or digitalhardware circuit(s) with software/firmware, or any portions of hardwareprocessor(s) with software (including digital signal processor(s)),software, and memory(ies) that work together to cause an apparatus toperform various functions).

Although specific embodiments were described herein, the scope is notlimited to those specific embodiments. Rather, the scope is defined bythe following claims and any equivalents thereof.

1. A remote tester of a wiring harness test system, the remote testercomprising: a connector member comprising a terminal end having one ormore terminals configured to mate with terminals in an electricalconnector of a wiring harness, and a back end opposite the terminal end;and a tester control member integrated on the back end of the connectormember; wherein the tester control member includes: a housing thatprotrudes from the back end of the connector member; test circuitrywithin the housing that is electrically coupled to the terminals of theconnector member; a wireless transceiver within the housing that isconfigured to communicate with a central controller of the wiringharness test system to receive a test program; and a battery within thehousing that is configured to provide power to the test circuitry andthe wireless transceiver; wherein the test circuitry is configured toperform a test on the wiring harness based on the test program, and toreport test results to the central controller via the wirelesstransceiver.
 2. The remote tester of claim 1, wherein: the housingincludes a side wall disposed between the back end of the connectormember and an end wall.
 3. The remote tester of claim 2, wherein: thehousing further includes a removable access cover at the end wall thatallows access to an interior of the housing.
 4. The remote tester ofclaim 1, wherein: the housing has a cylindrical shape that fullyencloses the battery, the wireless transceiver, and the test circuitry.5. The remote tester of claim 1, wherein: outer dimensions of thehousing correspond with outer dimensions of the connector member.
 6. Theremote tester of claim 1, wherein the tester control member furtherincludes: a charging port configured to interface with a chargingconnector to charge the battery.
 7. The remote tester of claim 1,wherein the tester control member further includes: a pairing buttonconfigured to activate a pairing mode; and a pairing indicatorconfigured to indicate that the remote tester is paired with the centralcontroller.
 8. The remote tester of claim 1, wherein the tester controlmember further includes: a connector indicator configured to display anelectrical connector identifier for the electrical connector of thewiring harness.
 9. A wiring harness test system, comprising: a pluralityof remote testers configured to couple with electrical connectors of awiring harness; and a central controller configured to communicatewirelessly with the remote testers; wherein the remote testers include:a connector member comprising a terminal end having one or moreterminals configured to mate with terminals in one of the electricalconnectors of the wiring harness, and a back end opposite the terminalend; and a tester control member integrated on the back end of theconnector member; wherein the tester control member includes: a housingthat protrudes from the back end of the connector member; test circuitrywithin the housing that is electrically coupled to the terminals of theconnector member; a wireless transceiver within the housing that isconfigured to communicate with the central controller to receive a testprogram; and a battery within the housing that is configured to providepower to the test circuitry and the wireless transceiver; wherein thetest circuitry is configured to perform a test on the wiring harnessbased on the test program, and to report test results to the centralcontroller via the wireless transceiver.
 10. The wiring harness testsystem of claim 9, wherein: the housing includes a side wall disposedbetween the back end of the connector member and an end wall.
 11. Thewiring harness test system of claim 10, wherein: the housing furtherincludes a removable access cover at the end wall that allows access toan interior of the housing.
 12. The wiring harness test system of claim9, wherein: the test circuitry is configured to selectively inject acurrent onto one or more of the terminals of the connector member, andto selectively monitor for current on one or more of the terminals ofthe connector member.
 13. The wiring harness test system of claim 9,wherein: the wiring harness comprises a wiring harness of an aircraft.14. The wiring harness test system of claim 9, wherein the testercontrol member further includes: a charging port configured to interfacewith a charging connector to charge the battery.
 15. The wiring harnesstest system of claim 14, further comprising: a charging stationcomprising a plurality of docking ports; wherein the docking portsinclude the charging connector configured to couple with the chargingport.
 16. The wiring harness test system of claim 15, wherein thecharging station further includes: a battery level indicator at thedocking ports configured to indicate a battery level of the battery inone of the remote testers.
 17. The wiring harness test system of claim15, wherein the charging station further includes: a test selectionindicator at the docking ports configured to indicate whether a remotetester is selected for the test process on the wiring harness.
 18. Thewiring harness test system of claim 9, wherein the tester control memberfurther includes: a pairing button configured to activate a pairingmode; and a pairing indicator configured to indicate that a remotetester is paired with the central controller.
 19. The wiring harnesstest system of claim 9, wherein the tester control member furtherincludes: a connector indicator configured to display an electricalconnector identifier for one of the electrical connectors of the wiringharness.
 20. A method of testing a wiring harness, the methodcomprising: selecting remote testers of a wiring harness test systemthat mate with electrical connectors of the wiring harness, wherein theremote testers each include a connector member comprising a terminal endhaving one or more terminals configured to mate with terminals in one ofthe electrical connectors of the wiring harness, and a tester controlmember integrated on a back end of the connector member that includes ahousing that protrudes from the back end of the connector member, testcircuitry within the housing that is electrically coupled to theterminals of the connector member, a wireless transceiver within thehousing, and a battery within the housing that is configured to providepower to the test circuitry and the wireless transceiver; pairing theremote testers with a central controller of the wiring harness testsystem; coupling the remote testers to the electrical connectors of thewiring harness; and performing a test process by: transmitting a testprogram from the central controller to the remote testers via wirelesssignals; performing, at the remote testers, a test on the wiring harnessbased on the test program; reporting test results for the test processfrom the remote testers to the central controller via wireless signals;and verifying, at the central controller, a condition of the wiringharness based on the test results.